Hinged weatherproof electrical box cover

ABSTRACT

The present invention is directed to a weatherproof electrical outlet box assembly for shielding and protecting electrical components from moisture including a faceplate for attaching to an outlet box, the faceplate being substantially planar, and perimetrically bounded by a substantially rectangular side edge, the faceplate having at least one aperture for receiving an electrical component and; the faceplate including a first hinge socket and a second hinge socket extending respectively from the side edge in substantially orthogonal orientation. The weatherproof electrical outlet box assembly further including a cover having a front wall, an opposed open end and a substantially rectangular perimetrical side wall therebetween defining a cover interior, the side wall having a rim bounding the open end, the cover including at least one access port through the side wall adjacent the open end for providing separate passageways into the interior of the cover; the cover including a first hinge pin and a second hinge pin extending respectively from the side wall adjacent the open end in substantially orthogonal orientation; and the cover being pivotally affixed to the faceplate by operative engagement of the hinge socket with the hinge pin of corresponding orientation and movable between an open and a closed position and wherein the hinge pin and the hinge socket that are not in operative engagement are not aligned.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of and claims priority to U.S.application Ser. No. 11/414,704 filed Apr. 28, 2006 now U.S. Pat. No.7,235,740, which is continuation of U.S. application Ser. No.10/901,392, filed July 28, 2004 now U.S. Pat. No. 7,241,952, which is acontinuation of U.S. application Ser. No. 10/353,121, filed Jan 28,2003, now U.S. Pat. No. 6,891,104, which are incorporated herein byreference.

FIELD OF THE INVENTION

This invention relates to a hinged electrical connection box cover forcovering electric and/or electronic components, having a cover body,comprising a bottom and side walls, and open top defined by the saidwalls, wherein the cover can be closed over a selectivelyinterchangeable faceplate, that is rigidly mounted to accommodate anelectrical component and pivotally attached to the cover wherein thehinged front cover can be opened and closed whether the faceplate isoriented about either a horizontal or vertical axis, and provideweatherproof protection to the electrical component.

BACKGROUND OF THE INVENTION

Electrical boxes are used for a variety of applications wherein it isnecessary to provide a termination point for electrical wires forsplicing or connection to an electrical component. An electrical box isrigidly mounted on or in a wall in such locations to conveniently locatean electrical component. Depending on the application and location,electrical boxes can be mounted either in a horizontal or verticalorientation. Once mounted, the wires installed and connected to theelectrical component therein, the box is closed with a face plate. Theface plate must be chosen to match the installed electrical component,and covers the top opening of the connector box, thus preventing anydamage to the components mounted in the box or accidental contact withlive electrical wires.

Due to the varied needs for electrical power and switching, it issometimes necessary to mount a box in a location where it will beexposed to wet conditions. Typically, such installations can include anoutdoor receptacle to provide electricity for lighting, power tools orappliances. When used in a location where the connector box will beexposed to water, it is necessary to provide for structure to ensurethat water does not enter the box and thereby damage the componentstherein or cause a “short circuit”. An effective way to prevent waterfrom entering an electrical box is to provide a cover for the faceplatethus providing a weatherproof seal.

It would therefore be desirable to have an electrical connector boxcover that can provide a weatherproof seal, with an exchangeablefaceplate wherein the cover can be adapted to be used with a connectorbox that is mounted in either a horizontal or vertical orientation.Additionally it would be desirable to provide for a hinge on thefaceplate such that the cover can be pivotally opened for gaining easyaccess to the components that are shielded by the cover. Additionally itwould be useful for the cover to be adapted to be opened when thefaceplate is oriented in either the horizontal or vertical directionwithout the need to modify the cover or the faceplate and provide alocking mechanism whereby the cover can be secured regardless of whichposition the box is mounted.

SUMMARY OF THE INVENTION

The present invention is therefore directed to a weatherproof electricaloutlet box assembly for shielding and protecting electrical componentsfrom moisture comprising a faceplate for attaching to an outlet box, thefaceplate being substantially planar, and perimetrically bounded by asubstantially rectangular side edge, the faceplate having at least oneaperture for receiving an electrical component and; the faceplateincluding a first hinge socket and a second hinge socket extendingrespectively from the side edge in substantially orthogonal orientation.The present invention further including a cover having a front wall, anopposed open end and a substantially rectangular perimetrical side walltherebetween defining a cover interior, the side wall having a rimbounding the open end, the cover including a at least one access portthrough the side wall adjacent the open end for providing separatepassageways into the interior of the cover; the cover including a firsthinge pin and a second hinge pin extending respectively from the sidewall adjacent the open end in substantially orthogonal orientation; andthe cover being pivotally affixed to the faceplate by operativeengagement of the hinge socket with the hinge pin of correspondingorientation and movable between an open and a closed position andwherein the hinge pin and the hinge socket that are not in operativeengagement are not aligned.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the front of the electrical connectorbox cover and attached faceplate in a horizontal position, the cover andfaceplate being in a closed position.

FIG. 2 is a perspective view of the electrical connector box cover andattached faceplate in a vertical position, the cover and faceplate beingshown in a open position.

FIG. 3 is a detailed perspective view of the locking device and hinge ofthe electrical connector box and faceplate according to the presentinvention.

FIG. 4 is a detailed perspective view of the inside of electricalconnector box cover rim and knockout according to the present invention.

FIG. 5 is a partial cross-sectional view of the electrical connector boxcover and faceplate according to the present invention as seen alongviewing lines V-V of FIG. 1.

FIG. 6 is a perspective view of an alternate embodiment of the faceplateaccording to the present invention.

FIG. 7 is a perspective view of another alternate embodiment of thefaceplate according to the present invention.

FIG. 8 is a perspective view of the electrical connector box cover andattached faceplate in a horizontal position, the cover and faceplatebeing in an open position.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

There will be detailed below the preferred embodiments of the presentinvention with reference to the accompanying drawings. Like members aredesignated by like reference characters in all figures.

The present invention is directed to a weatherproof cover for anelectrical connector box for providing water protection to componentsaccommodated therein without the use of a gasket, having selectivelyinterchangeable faceplates for adaptation to a variety of electricalcomponents and which can be utilized with a connector box mounted ineither a horizontal or vertical orientation.

Turning now to FIG. 1, the electrical connector box cover 100 of thepresent invention is shown. The electrical connector box cover 100 is agenerally rectangular box-like member having a substantially planarrectangular front 102 that is perimetrically bounded by an outer wall104, that is comprised of four substantially planar side walls havingtwo sets of substantially parallel sides. The outer wall 104 extendsbackwardly from the front 102 and has an outwardly flanged rim 106 atthe back with an outside edge 108. The rim 106 is preferably integrallyformed on cover 100 as a single piece component.

Depicted on outer wall 104 is a conventional plug knockout 110 of a typewhich is known in the art. The knockout 110 is a partially cut throughopening or removable wall section. The knockout 110 is removed to createan opening through which a wire may pass for electrical connection tothe enclosed device. In the embodiment shown, once the knockout has beenremoved it cannot be reinstalled. While knockout 110 is depicted on onesurface of outer wall 104, it will be appreciated that a plurality ofknockouts can be positioned on any surface of the outer wall. It shouldbe noted that while the edge of knockout 110 does not appear to extendonto flanged rim 106, as will be seen in FIG. 2, the partially cutthrough opening on the inside of outer wall 104 reaches the edge of theouter flange. Therefore, the portion of rim 106 adjacent the knockout110 is removed to form an unobstructed aperture. In addition, in FIG. 1there is depicted horizontal hinge socket 112 in pivotal engagement withhorizontal cover hinge pin 114. Cover locking device 116 is also shownin operative engagement with faceplate locking member 126 as explainedin greater detail with respect to FIG. 3. As is well known, coverhousing 100 may be formed of a variety of materials. In the particularembodiment depicted here, cover housing 100 is integrally formed of aninjection molded, high impact synthetic plastic material, such as forexample, clear Lexan.

With further reference to FIG. 1, horizontally oriented cover 100 isshown in a closed position with respect to a faceplate 120. Shown inFIG. 1 is faceplate side edge 122, faceplate locking devices 124 and126, and faceplate vertical hinge socket 128. Locking devices 124 and126, extend from diagonally opposed corners of faceplate side edge 122and are adapted to be fastened to complementary cover locking device116. Locking device 126 is shown in locking engagement with coverlocking device 116 as described below. In this view, cover 100 isdepicted as pivotally engaged to faceplate 120 in a horizontalorientation. As will be further described and depicted in FIG. 2, cover100 can also be pivotally engaged to faceplate 120 in a verticalorientation.

Turning again to FIG. 2, there is shown vertically oriented cover 100 ofthe present invention depicted in an open position with respect tofaceplate 120. Visible in the open position is the interior ofrectangular front 102 and outer wall 104, having an edge 202 thatdefines an opening into cover interior 204, exterior rim 206 andvertical cover hinge pin 208 which is oriented horizontally during use.Visible on the interior surface of outer wall 104 are the partially cutthrough openings 209 forming knockouts 110. Faceplate 120 has an insidesurface 210 (facing the inside of cover 100) and an outside surface 212(not visible), perimetrically bounded by a side edge 122. The faceplatedepicted is adapted to accommodating a single duplex receptacle, havinga pair of openings 214, which are positioned such that the faceplatewill fit flush over the duplex receptacle when installed. However,faceplate 120 may be modified and configured to adapt to any number ofelectrical components, as depicted and described for example, in FIGS. 6and 7. There is further shown a plurality of holes 216 a and 216 b forreceiving fasteners, for example screws to attach the faceplate to avariety of different components, such as a duplex receptacle. Verticalhinge socket 128 (which is oriented horizontally during use) extendsfrom side edge 122 for pivotally connecting to the vertical hinge pin208. There is further defined on the outside surface of the faceplate, acontinuous protrusion 220 around the perimeter of the faceplate.Protrusion 220 is preferably integrally formed on the faceplate and ispositioned on the faceplate such that it aligns with the inside edge ofthe outwardly flanged rim to form a seal as described below. A concavechannel 222 is positioned along the inside edge of the continuousprotrusion 220. Concave channel serves to provide a barrier to watermigration into the interior of cover 100 along the inside surface offaceplate 120.

Turning now to FIG. 3 there is shown a detailed view of a portion of theexterior of cover 100 and faceplate 120 showing cover locking device 116and faceplate locking device 126. The same will also be true withrespect to faceplate locking device 124. More particularly, FIG. 3 showslocking device 126 in locking engagement with cover locking device 116.Cover locking device 116 comprises a stanchion 302 supporting an annularring 304 comprised of an inside semi circle 304 a, and outside semicircle 304 b and a locking tab support lip 306. Faceplate locking device126 comprises a support 308 stanchion, an annular ring (not visible)which is comprised of an inside semi circle and an outside semi circle,similar to structures 304 a and 304 b, and a locking tab 312. Annularring 304 is adapted to align concentrically with the complementarystructure on faceplate locking device 124 or 126, and provides a passagethrough which a conventional lock shank of a padlock or other lockingdevice (not shown) may be inserted. The lock can be a padlock, opened bykey or combination. Annular ring 304 and the annular ring of lockingdevice 124 and 126 are formed of offset semicircular portions therebyproviding a gap between the structures for locking tab 312 to passthrough. Furthermore, the locking device includes a snap closuremechanism that can be of a variety of types that are well known in thelatching arts. In this exemplary embodiment depicted, the snap closuremechanism comprises the locking tab support lip 306 and locking tab 312.Tab 312 is a post having four sides, projecting upwardly from faceplatelocking device 124 or 126, wherein the side located adjacent the coverlocking device has a ramped or angled surface, with a notch 314 belowthe angled surface adapted to engage locking tab support lip 306 asshown in FIG. 3. The tab 312 is shown extending upwardly from lockingdevice 124 and 126. Both the tab 312 and tab support lip 306 arepreferably formed integrally with cover 100 and faceplate 120respectively from a resilient material.

In operation, when cover 100 is pivotally engaged to faceplate 120 androtated to a closing position, cover locking device 116 passes faceplatelocking device 124 or 126, whereby resilient locking tab 312 iselastically deformed laterally away from locking device 116, until cover100 is in the fully closed position. Once cover is fully closed, lockingtab 312 springs back to its original position to releasably secure cover100 on faceplate 120 whereby notch 314 engages locking tab support lip306. At the same time annular ring 304 and the annular ring of lockingdevice 124 or 126 are concentrically aligned in order to permit theinsertion of a lock such as a pad lock. In the specific embodiment ofFIGS. 1 and 2, two locking devices 124 or 126 having resilient tabs 312are provided on faceplate 120, located at the edge of the faceplate ondiagonally opposed corners for securely retaining the cover 100 againstthe faceplate 120. To open cover 100, the resilient tab 312 is manuallybent away from locking device 116, whereby notch 314 disengages fromlocking tab support lip 306, permitting opening of the cover. Byproviding a cover and faceplate with a snap closure mechanism, the covercan be closed securely and tightly, thus maintaining a tight sealbetween the cover and faceplate.

Turning now to FIG. 4, there is shown a detailed view of a portion ofcover interior 204. More particularly there is shown, cover supportledge 402, exterior rim 206, having an inside edge 404, an outside edge406 and a top edge 408. Further, visible on the interior surface ofouter wall 104 are the partially cut through openings 209 of knockouts110. The partial cut through opening comprises a “u-shaped” incision onthe interior of outer wall 104 and exterior rim 206. The incisionweakens the outer wall and rim structure whereby a portion of that wall,the knockout 110, can be easily removed to create a passage way throughthe cover. As previously noted, the partially cut through opening 209,extends to the exterior rim 206, thereby enabling removal of thatportion of rim 106.

FIG. 5 depicts the cover 100 and faceplate 120 of the current inventionas described above along cross-section V-V of FIG. 1. Extending from theinside surface 210 of faceplate 120 is continuous protrusion 220,located around the perimeter of the faceplate and having an innerperiphery 502, an outer periphery 504 and a intermediate sealing surface506. Extending from the edge of the outer periphery 504 to side edge 122is faceplate lip 510 wherein the bottom surface forms an outer sealingsurface 512. Located along the inner periphery 502 of continuousprotrusion 220 is a concave channel 222 that forms a depression in thesurface of the faceplate. When cover 100 is closed, inner sealingsurface 506 bears upon cover support ledge 402 and outer sealing surface512 bears upon top edge 408 of cover 100 to form a seal.

In use, when cover 100 is closed, any water which may fall on the coveris channeled away from the cover and faceplate joint by the outwardlyflanged rim 106. Furthermore, there is a mechanical barrier to preventwater from entering cover 100 by means of a close tolerance fit betweenthe outer sealing surface 512 and the flange top edge 408. In addition,there is a secondary mechanical barrier by means of a close tolerancefit between the support ledge 402 and inner sealing surface 506.

Now turning to FIG. 6 there is shown a perspective view of the outsidesurface of an alternate embodiment of the faceplate 600 according to thepresent invention. The embodiment shown in FIG. 6 is adapted to cover aGFCI electrical receptacle, having an substantially rectangular aperture602 adapted to receive a GFCI outlet. In addition, it would be apparentto one skilled in the art, that faceplate 600 can be adapted to covervarious electric or electrical components as also shown and described,for example in FIGS. 2 and 7. The faceplate according to the presentinvention is selectively interchangeable according to the needs of auser. Alternate embodiments of faceplate 600 are adapted to cover avariety electrical components.

In addition, FIG. 6 depicts apertures 216 b having a keyhole shape forattaching the faceplate to a wall outlet, such as a receptacle box. Thekey hole apertures includes a substantially circular opening 610, aslotted region 612 and a concave depression 614 surrounding the slottedregion. The circular opening 610 is adapted for receiving an outwardlyflanged fastener head, such as a screw head (not shown). The innerdiameter of the circular opening 610 is substantially equal to thediameter of the fastener head to be received. Extending radially fromthe outer circumference of the circular opening is slotted region 612,which has a width less than the diameter of the circular opening andsubstantially equal to the diameter of the fastener shank to bereceived. Furthermore, there is provided a concave depressionsurrounding the slotted region, for retaining the fastener head.

In use, faceplate 600 is affixed to a wall outlet by positioning thecircular openings 610 in alignment with fasteners that are secured to amounting box. The head of the fasteners, typically screws, protrudethrough circular openings 610 once the faceplate has been attached tothe mounting box. Faceplate 600 is then displaced laterally such thatthe fastener shank is received by slotted region 612 while the fastenerhead is retained within the concave depression thereby securelyretaining the faceplate to the mounting box.

Also shown in FIG. 6 is a detailed view of hinge support sockets 112 and128, comprising an arched structure 616, with a curved interior 618 anexterior 620 and a hinge pin retaining tab 622. The interior 618 portionis adapted to concentrically receive either hinge pin 114 or 208 ofcover 100. Hinge socket 128 is mounted on faceplate 600 such thatinterior portion 618 is oriented towards the front of faceplate 600. Bymounting the hinge socket in this way, hinge pin 114 can be rotatablyengaged to hinge socket 128 either before or after faceplate 600 hasbeen securely affixed to an electrical component mounting box.

In operation, the open portion of a hinge socket is fit over a hinge pinand snapped into place such that retaining tab 622 is elasticallydeformed to permit the hinge pin to fit concentrically within the archinterior 618. Once in place, retaining tab 622 resiliently bears uponthe hinge pin to hold it within the hinge socket. Cover 100 can therebybe pivoted to rotate into an open or closed position.

FIG. 7 depicts an alternate embodiment of a faceplate according to thepresent invention, having a rectangular knockout plug 710, adapted foruse with a light switch, for example, and a circular knockout plug 712adapted to receive a single round receptacle, such as, for example, anelectrical socket typically used for 220v service. The faceplate can beadapted to either use by removing the appropriate knockout plug,however, once the knockout plug is removed, it can not be replaced. Inaddition, while the faceplate of FIG. 7 is depicted as having a roundand rectangular knockout plug, it would be apparent to have a faceplatehaving knockout plugs of a variety of alternate shapes for use withdifferent electrical components.

The faceplate embodiments depicted in FIGS. 2, 6 and 7 are exemplaryonly, since it would be apparent to have a faceplate according to thepresent invention adapted to receive a variety of alternate electricalcomponents.

FIG. 8 depicts the electrical connector box cover 100 and faceplate 120of the present invention in the open horizontal orientation, whereincover 100 is rotated 180 degrees from the orientation depicted in FIG. 2with respect to faceplate 120. In this view, hinge pin 114 and hingesocket 112 are pivotally engaged. While in either the horizontal orvertical position, the unused hinge socket and pin are positioned alongopposite parallel sides of the faceplate and cover device respectively.Such arrangement prevents the unused hinge components from interferingwith the opening and closing of the cover. Furthermore, in thehorizontal orientation, cover locking device 116 engages with faceplatelocking device 124. Locking element 126 is not engaged in theorientation shown in FIG. 8.

In operation, the faceplate, is rigidly mounted on an electricalcomponent box, typically using screws. The component box can be anin-wall installation, or surface mounted wherein the box is affixed to abuilding structure, such as a wall or column. In one embodiment of thepresent invention, there is provided one outlet box cover 100 togetherwith multiple faceplates, such as, for example those depicted in FIGS.2, 7 and 8. The faceplate can be selectively chosen from among thoseprovided to cover the electrical component, and mounted on an outlet boxin either a horizontal orientation or vertical orientation. Unusedfaceplates can be discarded. Once faceplate 120 is securely mounted, thecover is attached to the faceplate using the hinges provided. The hingesockets located on faceplate 120 are oriented such that the hinge pincan be pushed into the hinge socket and thereby resiliently retained bytab 622. The hinge socket orientation, makes it possible to affixed thecover to the faceplate after the faceplate is securely mounted to thewall. To affix cover 100 to faceplate 120, either hinge socket 128 or112 is pivotally engaged to the corresponding horizontal 114 or vertical208 hinge pin respectively. Either set of hinges can be selectivelyengaged without the need to modify the faceplate or the cover. It shouldalso be understood that other intermating structure are equally suitablesuch that the described pin and socket interconnection is not the onlystructure usable for securing the cover to the faceplate. For example,the pin structure described could be secured to the faceplate and thesocket structure could be secured to the cover. Bayonet, ball,male/female and even hermaphroditic structure are equally suitable forthis purpose. Furthermore, there is no necessity that the intermatingstructure on the faceplate be the same nor is there any necessity thatthe intermating structure on the cover be the same. It is only necessarythat the respective intermating structure on the cover and faceplate beconfigured to intermate or engage each other.

In the preferred embodiment of the present invention, the faceplate andcover are mounted such that the cover opens by pivoting in an upwarddirection. For example, the faceplate is mounted with either a verticalor horizontal hinge socket positioned at the top wherein thecorresponding cover hinge pin is pivotally engaged to that socket.Alternately, it is also possible to open the cover in a downward orlateral direction by positioning a hinge socket at the bottom or side ofthe faceplate respectively, and pivotally engaging the correspondinghinge socket. Either orientation can be achieved without anymodification to the faceplate or cover.

Once the faceplate and cover are pivotally engaged and the cover isclosed, the preferred embodiment includes a locking device to maintainthe cover in a closed position. As previously described, the lockingdevice may include an annular ring for engaging a lock shank such as apadlock and a latching mechanism such as, for example, the snap devicedepicted and described in FIG. 3.

It will be appreciated that the present invention has been describedherein with reference to certain preferred or exemplary embodiments. Thepreferred or exemplary embodiments described herein may be modified,changed, added to or deviated from without departing from the intent,spirit and scope of the present invention. It is intended that all suchadditions, modifications, amendments, and/or deviations be includedwithin the scope of the claims appended hereto.

1. A weatherproof electrical outlet box cover assembly for shielding andprotecting electrical components from atmospheric elements comprising: afaceplate for attaching to an electrical outlet box, including amounting surface having opposed lateral sides and opposed longitudinalsides and at least one aperture on said mounting surface closelyconforming to an electrical component, said faceplate further includinga pair of first hinge mating assemblies, one of said first pairextending in a first orientation from one of said lateral sides and theother of said first pair extending in a second orientation from one ofsaid longitudinal sides; and a cover having a front wall, and opposedlateral side walls and opposed longitudinal side walls defining a coverinterior, said cover further including a pair of second hinge matingassemblies, one of said second pair extending in a first orientationfrom one of said lateral side walls and the other of said second pairextending in a second orientation from one of said longitudinal sidewalls walls; said cover being pivotally affixed to said faceplate byoperative engagement of one of said first hinge mating assemblies withone of said second hinge mating assemblies of corresponding orientationand movable between an open and a closed position wherein the other ofsaid first hinge mating assemblies and the other of said second hingemating assemblies that are not in operative engagement are on opposedsides of the cover assembly.
 2. A weatherproof outlet box cover assemblyof claim 1 where said faceplate is integrally formed.